Extrusion Press Maintenance Manual

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We are pleased to present the latest edition of the Extrusion Press Maintenance Manual.

The new 416-page manual is designed to assist plant engineers and maintenance managers, especially in cases where experienced maintenance people have retired or original manuals have been lost.  It will be valuable for training new workers, for documenting procedures for ISO 9000 certification, and as general information for extrusion companies' upper management.

This unique manual, which documents in detail all aspects of extrusion press maintenance, was prepared by drawing on my 30 years of experience in the extrusion industry, and on published references.  In addition, selected presentations by industry experts on several critical topics, such as electrical and hydraulic system maintenance and repair of major components, have been incorporated in the manual with permission of the authors.

The loose-leaf manual contains some 317 illustrations plus tables, charts, and useful references, as well as Preventive Maintenance Schedules in spreadsheet format, to permit the user to customize the schedules for individual requirements.

To order the manual online please go to the Home page above !!  If you require immediate delivery, the complete manual is available in Adobe pdf format by large file transfer (50 Mb) for US$ 50. 

USD$50 - Manual by electronic transfer - *.pdf format (large file transfer).  PLEASE INCLUDE E-MAIL ADDRESS.

click here to DOWNLOAD A SAMPLE of Chapter 3 - Tooling

Table of Contents for the Extrusion Press Maintenance Manual:


  • Acknowledgments
  • References
  • Useful Tables:
  • Conversion of Units
  • Temperature Conversion
  • Calculating Stretcher Capacity - English Units
  • Calculating Stretcher Capacity - Metric Units
  • Weight of Extrusion Billets
  • Press Specific Pressure - English Units
  • Press Specific Pressure - Metric Units
  • Millimeter Conversion
  • Time Limits for Tooling in Oven at Temperature
  • Thermocouple Types
  • Glossary of Terms for Press Components
  • Diagrams of Press Components

Routine Inspection and Maintenance

  • Scheduled Maintenance
  • Mechanical Maintenance
  • Lubrication
  • "Preventive Maintenance Program Recommendations" (The Voice of Experience), by David Turnipseed
  • Daily Check Sheet Procedure
  • Daily Check Sheet (Sample)
  • Press Troubleshooting Chart
  • "Extrusion Press Maintenance - A Predictive Approach" (The Voice of Experience) by P. Gopalan Kutty, Gulf trusions, Dubai
  • Farrel Maintenance Training Course information:
  • Press Installation
  • Mechanical Functions of an Extrusion Press
  • Mechanical Maintenance

Press Alignment

  • Alignment Procedures
  • Recommended Tools
  • Alignment and Leveling of the Fixed Press Components
  • Alignment of the Moving Press Components
  • Use of the Alignment Tool Stack
  • Quick Checks of Press Alignment
  • Modifying the Press for Easier Adjustment of Alignment
  • "Extrusion Press Alignment with Modern Technology," by J.E.V. Mulder and G.J. Smith, University of Otago, New Zealand


  • Fixed Dummy Blocks
  • Loose Dummy Blocks
  • Clean-out Blocks
  • Stem
  • Container
  • Container Liner
  • "Extrusion Container Care and Maintenance," by James M. Pope, Special Projects Consultant to Lake Park Tool
  • Improvements to Container Design
  • "Preventive Maintenance of Extrusion Tooling," by Gary Dion, Extrusion Consultant Minimizing the Occurrence of Flared Billets
  • "Lubrication of Extrusion Press Tooling" by James Dyla, Amcol Corp.

Inspecting and Repairing Major Components

  • Procedure for Repairing Cracked Main Cylinder
  • How Major Components are Designed and Tested
  • "Adapting Extrusion Presses for a High Cycle Fatigue Load Environment," by J.O. Nøkleby, Det Norske Veritas
  • In-Service Inspection, Repair, and Trouble-Shooting
  • Failed Components - Repair or Replace?
  • Requirements for Replacement Components
  • "Catastrophic Failure: A 48 Hour Remedy," by Rick Colden and Adam Cramlet, Alexandria Extrusion

Hydraulic Equipment

  • Hydraulic Oil
  • Filtration
  • Temperature
  • Sampling & Analysis
  • Air Breather
  • Pumps
  • Valves
  • Piping
  • Pressure Gauges
  • System Documentation
  • Troubleshooting
  • "Proper System Maintenance to Avoid Contamination and Cavitation," by Jack Hayes, Oilgear
  • Farrel Maintenance Training Course information:
  • Hydraulic Maintenance
  • Right and Wrong Ways to Install Hydraulic Tubing and Fittings
  • Troubleshooting Hydraulic Problems
  • Glossary of Hydraulic Terms
  • ISO/CETOP Hydraulic Symbols
  • Oilgear Training Bulletins:
  • Hydraulic System Survival Techniques #90012
  • Filtration Recommendations #90007-D
  • Piping Information #90011-F
  • Resistance of Valves and Fittings to Flow of Fluids
  • Storage Recommendations #90006B

Electrical & Controls

  • Maintenance of Control Equipment
  • Container Heating
  • Electric Motors
  • "Extrusion Press Electrical Systems,"  by David Turnipseed
  • "Tips for Successful Electrical Trouble Shooting of Extrusion Equipment,"  by David Turnipseed

Billet & Log Infeed Systems

  • Billet/Log Infeed Conveyors
  • Billet/Log Heaters - Gas Fired
  • Refractory and Insulation
  • Thermocouple Probes
  • Combustion Systems
  • Billet Heaters - Induction
  • Log Shear
  • Log Saw
  • Billet Transfer Conveyor
  • Billet Lubrication

Profile Handling Systems

  • High Temperature Textile Materials
  • Lead-out Tables
  • Run-Out Conveyors
  • Water Quench Systems
  • Air Quench Systems
  • Saws and Shears for Hot Profile Cut-Off
  • Pullers
  • Profile Transfer Systems and Lift-Overs
  • Cooling Tables:
  • Walking Beams
  • Belt Conveyors
  • Stretchers
  • Saw Feed Conveyors
  • Finish or Cold Saws
  • Saw Blade Lubrication
  • Saw Length Gauges
  • Off-Load Conveyors
  • Profile Stackers

Age Ovens

  • Temperature Surveys
  • Basic Age Oven Configurations
  • Combustion Systems
  • Routine Combustion System Maintenance
  • Improving Age Oven Energy Efficiency

Die Ovens

Maintenance Schedules

  • When to Perform Extrusion Plant Maintenance
  • Master Maintenance Schedule
  • Daily Maintenance
  • Weekly Maintenance
  • Monthly Maintenance
  • Quarterly Maintenance
  • Six Months Maintenance
  • Annual Maintenance

Spare Parts

  • Recommended Spare Parts
  • Storage of Spare Parts

Modernizing Older Presses

  • Specifying a New Press
  • Modernizing the Press Feed Line
  • Modernizing the Handling System
  • Downstream Material Handling
  • Auxiliary Equipment
  • Vendor Request form for Press Upgrades
  • "The Extrusion Press Line for 2024: A Forecast," by Al Kennedy
  • Double-Length Run-out Systems

Safety & Environment

  • Extrusion Tooling Safety
  • Safe Lifting Techniques
  • Mechanical Press Equipment
  • Keeping Overhead Cranes Safe
  • Check List of Safety Hazards
  • Personal Protective Equipment
  • Lock-Out Tag-out Procedures
  • Environment

Managing Extrusion Plant Maintenance

  • The Maintenance Level Audit
  • Staffing and Required Skills
  • Maintenance Engineering
  • Equipment Information Files and History
  • Spare Parts Inventory
  • "Ten High-Tech Tools for Extrusion Plant Maintenance," by Al Kennedy

Prices: Book version:  $275 Now US$ 200, USB flash drive and shipping within USA included (add $95 for Priority air mail, required for orders outside the US)

USB flash drive version only: $145 Now US$ 50, air mail shipping included

To order the manual online, click on the Home page above !!